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Visual ManagementIntroduction
Thinking win, Win, WIN
Visual ManagementIntroduction
Marek Piatkowski – November 2016
Thinking win, Win, WIN
Visual ManagementIntroduction
Thinking win, Win, WIN
Introduction - Marek Piatkowski Professional Background
Toyota Motor Manufacturing Canada (TMMC) - Cambridge, Ontario from 1987-1994
TPS/Lean Transformation Consulting - since 1994 Professional Affiliations
TWI Network – John Shook, Founder Lean Enterprise Institute (LEI) – Jim Womack Lean Enterprise Academy (LEA) – Daniel Jones CCM/CAINTRA – Monterrey, Mexico SME, AME, ASQ, CME
Lean Manufacturing Solutions - Toronto, Canada
www.twi-network.com
Visual ManagementIntroduction
Thinking win, Win, WIN
Visual Management Definition: A process in which standards and actual conditions
become quickly visible in the workplace and are acted upon in a timely manner
Purpose: Visual Management enables Managers and employees to monitor progress of production and immediately see any interruption to production flow.
To allow them to quickly assess the situation (normal/abnormal) and to take immediate corrective action to return to normal (standard) conditions
To delegate decision making process to the lowest level of operation To eliminate dependency on few “decision makers”
Visual Management is how the Workplace, Team, Department talks to you and how quickly you can determine what is going on without asking too many questions
Visual ManagementIntroduction
Thinking win, Win, WIN
Visual Management Is this situation normal or abnormal? Is this good or bad? Do I need to take action? Any abnormality is identified immediately
process/operation – are all procedures being followed? equipment/machinery – are they producing good parts? expected levels of performance availability of materials, inventory
Purpose - to delegate the decision making process to the lowest level of the organization
implement audio-visual controls eliminate dependency on a few “decision makers”
Visual ManagementIntroduction
Thinking win, Win, WIN
Visual Management Visual Controls
equipment and/or material status identification “automotive dashboard” any abnormality identified immediately ability to see a problem at a glance problems are made a lot more visible in a clean and well organized
workplace. being able to see a problem is a first step towards solving a problem
Ability to determine at any time a status of process / operation equipment / machinery expected levels of performance / inventory
Visual ManagementIntroduction
Thinking win, Win, WIN
Shop Floor Visual Management Information Boards & Centers Hourly Tracking Boards Attendance Boards / Manpower Planning Boards Detailed Project Plans with clear mile stones – Project Boards Action plans in a Business Plan document Pareto Charts Top 5 or 10 analysis Business Planning Walls Problem Solving Displays Project Status Reports Employee communication board Process abnormality display
Visual ManagementIntroduction
Thinking win, Win, WIN
Visual Management Are they following Visual Management tools?
Monthly Quality Performance trends PPI Performance monthly for the year Top 10 analysis Pareto charts Hourly production tracking boards Escalation signals & procedures
What is the difference between them? Which ones will help you solve the problem now while you can still
positively impact the data above? The trend data should be a gauge of how well your daily
management is performing
Visual ManagementIntroduction
Thinking win, Win, WIN
Visual Tools: are the visual indicators that communicate and support the
workplace management process. make the current condition and target or goal clearly identifiable. are easy to understand – “Status at a Glance”. are created & maintained to allow “out of standard” conditions to be
immediately & easily recognized Visual Management:
is the use of various visual tools and controls to help run the business, while the results are not in their final tally, and you can still impact the outcome.
Shop Floor Visual Management
Visual ManagementIntroduction
Thinking win, Win, WIN
Electronic Production Status Boards: To track production basis in real time To provide instant updates To indicate targets and goals To show results per shift or per day Use red/yellow/green visual controls
Visual ManagementIntroduction
Thinking win, Win, WIN
Andon Boards: Audio - visual boards that communicate the status of equipment or a
production line To make the current condition clearly visible and identifiable Are easy to understand – Status at a Glance
Visual ManagementIntroduction
Thinking win, Win, WIN
Equipment Status Lights: To communicate the status of equipment or a production line To make the current condition clearly visible and identifiable
Call for Help: Visual indicators that communicate a need for help or equipment stop or breakdown
Equipment Status
Equipment Status
Visual ManagementIntroduction
Thinking win, Win, WIN
Down Time Clocks: A Down Time Clock is used to measure total duration of
machine stops – regardless of the reasons or causes In it’s simplest form it is an analog clock connected to the
“logic” of a machine or an automated process At the start of the shift the clock is reset to 12:00 When machine is operating – the clock is not running. When
the machine stops – the clock starts to run.
Visual ManagementIntroduction
Thinking win, Win, WIN
Production Status Boards Production Status Boards are located on the manufacturing floor to
provide instant information regarding status of the Operation Production Status Boards should be used by Managers and
Supervisors to frequently review: daily production results operational availability daily issues and concerns problem solving activities
Minimize response time to identify and to solve problems Involve and focus support teams on priority actions Share information with all the people involved, at the same time,
within a minimum lead time
Visual ManagementIntroduction
Thinking win, Win, WIN
Hourly/Daily Production Status Tracking Boards: To track production results in real time To provide instant updates To indicate targets and goals To show results per shift or per day Use red/yellow/green visual controls
Hourly Tracking Boards
Visual ManagementIntroduction
Thinking win, Win, WIN
Production Scheduling Boards: To display and update production schedule To monitor progress of production throughout the day To indicate any problems or issues
Visual ManagementIntroduction
Thinking win, Win, WIN
Shipping Boards: To display and update shipping schedule and status of
shipments Long term planning and visibility To indicate if shipments will be completed on time
Visual ManagementIntroduction
Thinking win, Win, WIN
Materials Management Boards: To indicate potential inventory problems To maintain min/max levels of inventory To indicate inventory levels
Visual ManagementIntroduction
Thinking win, Win, WIN
Updating Production Status Boards: Establish a process for updating the information Who is responsible for updating the Boards How frequently is the information updated What type of information needs to be displayed
Visual ManagementIntroduction
Thinking win, Win, WIN
Changing the World. One Kaizen at a timeThis presentation is an intellectual property of W3 Group Canada Inc.
No parts of this document can be copied or reproducedwithout written permission from:
Marek PiatkowskiW3 Group Canada Inc.iPhone: 416-235-2631
Cell: 248-207-0416
[email protected]://www.twi-network.com
Thinking win, Win, WIN
Visual ManagementIntroduction
Thinking win, Win, WIN
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